EP3489334A1

EP3489334A1 - A method of manufacturing of pillar candles

Info

Publication number: EP3489334A1
Application number: EP17461632.6A
Authority: EP
Inventors: Andrzej Wrobel; Monika Zawadzka-Basinska
Original assignee: Korona Candles SA
Current assignee: Korona Candles SA
Priority date: 2017-11-22
Filing date: 2017-11-22
Publication date: 2019-05-29

Abstract

A method of manufacturing of a pillar candle, comprising the steps of: forming (201) a shell (111); forming (202) a core (112) within the shell (111); introducing (203) a wick (130) into the core (112); wherein forming (201) the shell (111) is performed in a mould comprising a base (310) with a cavity (311) terminated by a lower stamp (312) movable within the cavity (311) and an upper stamp (320) configured to be introduced into the mould cavity (311) and comprises the steps of: providing (401, 501) a molten shell material into the mould cavity (311); introducing (403, 503) the upper stamp (320) into the mould cavity (311), thereby causing the molten shell material to fill in the free space between the outer walls of the upper stamp (320) and the inner walls of the cavity (311); solidifying (404, 504) the shell material; and pushing (405, 505) the shell (111) out of the mould cavity (311) by means of the lower stamp (312).

Description

TECHNICAL FIELD

The present disclosure relates to a method of manufacturing of pillar candles.

BACKGROUND

Typically, a pillar candle is formed from a solid or semi-solid body of flammable materials, such as lipids and waxes, and contains a combustible wick inserted within the body. When the candle wick is lit, the generated heat melts the body, and the resulting liquid flows up the wick by capillary action and is combusted. Typically, when the candle burns out, the flammable material spills around the surface on which the candle is positioned. The remaining portion of the wick is left unprotected and the flame may propagate towards the surface on which the candle is positioned, including other flammable objects surrounding or being in contact with the candle (such as a table, a tablecloth etc). Therefore, for safe operation, a pillar candle should be supervised during use.
To improve safety, a pillar candle may be positioned on a protective stand, such as a candlestick, which may have a decorative function. The disadvantage is that the user must invest in an additional accessory to use the candle safely. Moreover, the stand becomes contaminated with the molten flammable material and requires cleaning, which is problematic.
There are known various methods of manufacturing of pillar candles, depending on the desirable candle design, construction, functionality and safety of candle utilization.
Typically, a mass-scale process of manufacturing of pillar candles involves three steps: preparation of the wick, preparation of the wax and continuous moulding or extrusion of the candles. Although the two first steps of the process do not have a significant impact on the production efficiency (since the wick and the wax composition may be prepared in advance or they may be obtained from external sources), the moulding process is crucial for the production efficiency, and thus the total production costs.
In an automated manufacturing process, the moulding of pillar candles is performed by continuous moulding systems. The continuous moulding involves the introduction of the wick into the mould and pouring molten flammable material (such as wax) into a moulding table located above the moulds. Typically, the moulds are preheated, so that the wax can flow evenly into the moulds. Next, the wax solidifies inside the mould. Once the wax is solidified, the pillar candles are pulled upwards out of the moulds. Such continuous moulding process is used for manufacturing of cylindrical, tapered, or fluted pillar candles which (due to their shape) can be easily ejected from the mould.
Another known method of manufacturing of pillar candles involves candle extrusion, i.e. a process in which a crushed flammable material (such as paraffin wax) is forced through a heated die under pressure. The wax consolidates around the wick. Unlike moulding systems, extrusion systems produce a continuous length of a candle, which is then cut into desired sizes. Next, the tips of the candles are formed by rotatable cutters to form final products.
The following examples of methods of manufacturing of candles are known from patent literature.
A US patent application US2005/0158679 describes a method of production of the compression-moulded vegetable candle of high fragrance load. The candle is made of a composition consisting of vegetable wax and paraffin wax. The candle has a greater amount of vegetable-based wax than a paraffin wax. The production method involves preparation of agglomerated wax particles from a vegetable wax-based composition followed by introduction the wax particles into a compression mould to compress thereof. Next, the compressed wax particles are de-moulded to incorporate a wick and obtain a finished candle product. Subsequently, the candle is optionally encased with wax layer containing paraffin wax, wherein the encasing process involves placing the compressed vegetable wax based composition in the center of a mould, wherein the mould is greater in diameter than the compressed vegetable wax-based composition, and next liquefying of the encasing wax, pouring the wax into free space within the mould and allowing the wax to cool. The prepared candle shows good burn characteristic, including no leaking and no guttering.
A US patent application US2003/0022121 describes a method of manufacturing of candle formed from a vegetable-based composition consisting of vegetable-based compounds with the addition of insects wax in the amount of 3%, which enhances the candle removal from the mould. The method involves melting and blending the composition ingredients to produce a homogenous mixture, pouring the mixture at 140°F into candle aluminium mould and allowing the mixture to harden at room temperature overnight. Overnight, the mixture shrinks and can be easily released from the candle mould.
A US patent US7736145 describes a method of manufacturing candles with a straight wick. The method consists in pouring liquefied fuel into a jar with closed bottom, inserting a wick into the open lower end of a tubular wick enclosing means having airtight and permanently closed upper end which is opposite to the lower end such, that the wick is substantially completely contained within the tubular wick enclosing means. Subsequently the tubular wick enclosing means with the wick is inserted into the jar so that the wick support resists on the bottom of the jar or container, and the tubular portion of the device is held in a vertical orientation by resting within an orifice in a bar extending across and resting upon an upper lip of the jar. Next, the tubular wick enclosing means, after fuel hardening, is removed by applying an upward force on the tubular wick enclosing means, and the second layer of liquefied fuel is poured into the jar. This production method provides speeding up the manufacturing process.
A US patent application US2013/0249141 describes a method of manufacturing of cast block candles. The method involves cooling a candle mould to the temperature of 0 to 25°C, heating the flammable material to the temperature of 30 to 70°C, pouring a flammable material into the mould and pressing the flammable material within the mould.
A US patent application US2010/0072669 describes a method of manufacturing of solid ink sticks used in printers. The method includes preparing a solid ink paste, injecting a portion of the paste under pressure into a chilled mould having two separable shells forming ink stick cavities, and separating of the shells to release solid ink stick from the ink stick cavities.
A US patent US5871787 describes a liquid-cooled wax mould and a method of production of wax slabs and blocks by using thereof. The method involves recirculating a cooling medium within the moulds cooling system, wherein the moulds are joint together with the frame of the plates, next pouring molten wax into the cavities of the moulds and cooling the wax by the cooling medium to harden the formed slabs or blocks, and next separating the moulds from each other and removing the slabs or blocks from the cavities.
A US patent US7578670 describes a self-extinguishing candle and a method of production thereof. The candle is made of wax and comprises a series of wick appliances having an internal hollow channel longitudinally disposed within the body.
As follows from the above examples, the methods of manufacturing of pillar candles are varied and dependent upon desired candle design, construction and functionality. Namely, the more sophisticated the candle design and the candle functionality, the more complicated the manufacturing process, especially when implemented for a mass scale production.
Therefore, there is a need to provide a method of manufacturing of pillar candles that allows high production efficiency, especially when implemented for a mass-scale process, of pillar candles having a compact structure.

SUMMARY

There is disclosed a method of manufacturing of a pillar candle, comprising the steps of: forming a shell; forming a core within the shell; introducing a wick into the core; wherein forming the shell is performed in a mould comprising a base with a cavity terminated by a lower stamp movable within the cavity and an upper stamp configured to be introduced into the mould cavity and comprises the steps of: providing a molten shell material into the mould cavity; introducing the upper stamp into the mould cavity, thereby causing the molten shell material to fill in the free space between the outer walls of the upper stamp and the inner walls of the cavity; solidifying the shell material; and pushing the shell out of the mould cavity by means of the lower stamp.
The method may comprise providing the molten shell material into the mould cavity by pouring.
The method may comprise providing the molten shell material into the mould cavity by spraying.
The method may further comprise, before providing the molten shell material into the mould cavity, spraying the walls of the cavity with a liquid.
The method may comprise filling cooling channels of the upper stamp, the lower stamp and/or the base with a cooling medium while solidifying the shell material.
The method may further comprise after forming the core within the shell, introducing a non-flammable base material into the shell on the core to form a non-flammable base.
The method may further comprise embedding the wick within the non-flammable base.
The method may further comprise pressing together the shell, the core and the non-flammable base.
The method may further comprise applying a protective sheet to the non-flammable base.

BRIEF DESCRIPTION OF DRAWINGS

The object of the present disclosure is shown by means of example embodiments in a drawing, in which:

Fig. 1 shows schematically an example of a pillar candle, in a cross-sectional view, that can be manufactured by the method presented herein;
Fig. 2 shows schematically a block diagram of a process for manufacturing of pillar candles;
Fig. 3 shows schematically a first embodiment of a process of manufacturing of a candle shell;
Fig. 4 shows schematically a second embodiment of a process of manufacturing of a candle shell.

DETAILED DESCRIPTION

Fig. 1 shows, in a cross-sectional view, an example embodiment of a pillar candle that can be manufactured according to the method presented herein. The pillar candle has a body 100 comprising a core 112 and a shell 111 that surrounds the core 112 around the side surface(s) and the top of the core 112.
The pillar candle may further comprise a non-flammable base 120 located at the bottom of the core 112. In that case, the shell 111 may overlap also the side surface(s) of the non-flammable base 120.
The shell 111 is preferably made of various flammable or non-flammable materials, that melt and preferably evaporate upon the heat of a candle flame. The core 112 is made a flammable material or a mix of flammable materials, such as lipids or waxes. For example, the core can be made from at least one of: paraffin wax, animal wax, vegetable wax or/and oil, mineral wax and/or oil, synthetic wax and/or oil and beeswax. The core may also include liquid, semiliquid or solid polymers and stearic acids or other natural compounds. The core may also include fragrance, dye and/or pigment.
For example, the core 112 and the shell 111 may be made of the same flammable material. Alternatively, the candle shell 111 and the core 112 may be made of different flammable materials. In these cases, both the shell 111 and the core material are burnt up upon the heat of the candle flame. Yet alternatively, the shell 111 may be made of a non-flammable material, whereas the core 112 is made of flammable material - in that case, the non-flammable material of the core 112 may melt and evaporate upon the heat of the candle flame.
The pillar candle further comprises a combustible wick 130 extending along the core 112. The wick 130 has a top end 131, protruding out of the core top surface 112 and out of the shell 111 overlapping the core top surface. The wick 130 also has a bottom end 132 terminating at the bottom core surface or extending into the bottom non-flammable base 120 (if present).
The non-flammable base 120 can be made of a non-flammable material, thus when the whole flammable material of the core 112 and optionally a candle shell 111 is burnt out, the flame on the bottom end of the wick 132, which rests in the non-flammable base 120, extinguishes - because the bottom end of wick 132 terminates at the bottom end of the core 112 just above the non-flammable base 120 or is immersed in the non-flammable material of the non-flammable base 120. This improves the safety of the candle use. For example, the non-flammable base 120 may be made of particles of a solid substance, such as sand, salt, or other organic or inorganic non-flammable matter, mixed with a binder (such as water, starch, gypsum, carrageenan). The non-flammable base may be also made of a synthetic resin (such as an epoxy resin, polymer resin), a cement mass or a mix of a mineral filling material and synthetic resin and/or cement. The non-flammable base 120 can be a hard piece or may have gel-like properties.
For example, the non-flammable base may comprise 80% by weight of sand bound by 10% by weight of gypsum and 10% by weight of water.
Alternatively, the non-flammable base may comprise 40% by weight of salt bound by 40% by weight of starch and 20% by weight of water.
Alternatively, the non-flammable base may comprise 90% by weight of water bound by 4% by weight of carrageenan and 6% by weight of solubilizer.
Furthermore, the non-flammable base 120 may comprise at least one aromatic additive (in the total amount from 1% to 95% by weight) which emits a scent to the environment (also even when the pillar candle is not burning). Therefore, the pillar candle may act as an air refresher. Aromatic substances that can be added to the non-flammable base may include fragrances.
The non-flammable base 120 may further comprise a bottom protective sheet 121 to prevent the non-flammable base 120 from falling out of the body 100, for example during moving or lifting of the candle. Moreover, the protective sheet 121 may protect the surface on which the candle is placed from scratching the surface by the coarse particles of the non-flammable base 120 (if present and not covered by the binding substance). Moreover, the bottom protective sheet 121 may prevent the scent to be released from the inflammable base 140 in the case it comprises aromatic substances, during transportation and storage before use by the final user.
Moreover, the non-flammable base 120 can be encased by the shell 111 in order to prevent it from detaching from the core 112. The shell 111 tightly overlaps the side surface(s) of non-flammable base 120.
Furthermore, the candle shell 111 and/or the core 112 may also comprise aromatic substances (for example, in the amount from 0,1% to 95% by weight). The aromatic substances that can be added to the core 112 and shell 111 of the candle may include fragrances.
Fig. 2 presents schematically a block diagram of a method of manufacturing of pillar candles. The method involves forming 201 the shell 111, forming 202 the core 112 within the shell 111 by filling, introducing 203 the wick 130, optionally forming 204 the non-flammable base 120 (by inserting a pre-formed element or filling a non-flammable substance), pressing 205 and optionally securing a candle bottom with a protective sheet 206.
The process 201 of forming the shell 111 is shown in details in Figs. 4 and 5, in a first and second embodiment, respectively.
The shell 111 is formed in a mould such as shown in Fig. 3. The mould comprises a base 310 with a cavity 311 terminated by a lower stamp 312 movable within the cavity 311 and having a cross-section corresponding to the cross-section of the cavity 311. The walls of the cavity 311 define the outer shape of the shell 111 to be formed. The mould further comprises an upper stamp 320 configured to be introduced into the mould cavity 311. The upper stamp 320 has a cross-section smaller than the cross-section of the mould cavity 311. The walls of the upper stamp 320 define the inner shape of the shell 111 to be formed.
The upper stamp 320, the lower stamp 312 and the base 310, are provided with a cooling system having cooling channels 314 filled with a cooling medium, e.g. cold water, for speeding up the solidification of the wax, when present in the mould cavity 311.
To manufacture the candle, with the process as shown in Fig. 4 and 5, at step 401, 501 a molten material for the shell to be formed is introduced into the mould cavity 311, preferably by means of a heated nozzle 331.
As shown in Fig. 4, the molten shell material may be introduced by pouring 401 or, as shown in Fig. 5, the molten shell material may be sprayed 501 into the mould cavity 311 so as to evenly spray the bottom and the walls of the mould cavity 311 with the molten shell material.
Optionally, before the introduction of the molten shell material, at step 500, the cavity 311 walls may be sprayed with a liquid, such as water, oil (such as a vegetable oil, mineral oil or synthetic oil), liquid paraffin or glycol, by means of a cooling nozzle 332. This may allow forming an irregular outer surface of the shell, such as a matt surface, rustic surface.
After the molten shell material is input into the mould cavity 311, the upper stamp 320 is introduced into the cavity and it presses the shell material towards the cavity bottom in step 403, 503, so as to shape the material into a final form of the shell. This causes the shell material to move upwards the cavity, to fill in the free space between the outer walls of the upper stamp 320 and the inner walls of the cavity 311.
Next, in step 404, 504 the cooling channels 314 of the upper stamp, lower stamp and/or the base are filled with a cooling medium to speed up the solidification of the shell material. Therefore, the time of the process of shell-forming is shortened. After solidification of the shell, the upper stamp 320 can be removed from the cavity 311.
Subsequently, at step 405, 505, the solidified shell is pushed upwards out of the mould cavity 311 by means of the lower stamp 312.
After forming 201 the shell, the core material is introduced in step 202 into the interior of the formed shell 111. For example, a heated, foamed flammable mass may be poured into the shell 111 or a powdered mass ma be introduced into the shell 111, to form a flammable core 120. When introducing the core material into the shell 111, the shell is arranged upside down as compared to the shell arrangement during candle use, so that the material of the core fills the shell interior and adheres the shell walls, therefore forming a solid body inside the shell.
Preferably the flammable core material is introduced into the shell so as to fill 50% of the shell interior, or 70% of the shell interior, or 90% of the shell interior, or 95% of the shell interior. In case heated core material is introduced, the core is cooled down to solidify.
Next, at step 203 the wick 130 is introduced into the body so as to extend both ends of the wick out of the core 120 and out of the shell 111. For example, in order to introduce the wick, a hole is made in the body e.g. by introducing a heated rod into the body, or by drilling, or by laser beam and then (or simultaneously with making the hole) the wick is introduced into the hole. The wick may be rigid. The wick may be introduced into the body using a guide, such as a hollow tube.
Next, at step 204 the non-flammable base 120 can be formed by introduction the non-flammable base material into the shell on the core, so as to encase the end of the wick projecting from the core and to fill the remaining empty interior of the shell. The non-flammable base 120 solidifies and forms the bottom of the candle. The wick may be bent within the non-flammable base 120 (i.e. such that it passes along a line which is inclined with respect to the line of the wick within the flammable core 112), which additionally increases the holding force of the wick 130 inside the inflammable base 120. In other words, the wick is embedded within the inflammable base 120.
Subsequently, at step 205, the non-flammable base 120 may be pressed towards the flammable core 112, thereby facilitating the integration of the flammable substances of the core 112 with the non-flammable substances of the base 120. As a result, the flammable material may be mixed with the inflammable material within a border region between the flammable core 112 and the non-flammable base 120.
To protect the bottom of the non-flammable base 120 or to prevent the emission of the scent from the non-flammable base 120, the bottom of the candle can be secured with a protective sheet 121 in step 206. The protective sheet 121 preferably is attached to the free edges of the shell walls 111, overlapping the side surface of the non-flammable base 120, and optionally to the non-flammable base 120.
Next, the final products, i.e. pillar candles may be secured with a protective foil, packed in boxes and stored or directly sent to recipients.
The presented method of mass-scale candle manufacturing process provides a fast and easy way of production of pillar candles. Especially, the process features improved production efficiency due to the shortened time of forming of shells. This is caused by the developed a mould for forming the shell, provided with the cooling system enabling the shell to solidify faster.
Moreover, the candles obtained by the method of the present disclosure feature a compact design and enhanced fire safety in use due to the use of a non-flammable base adhered to the flammable core, wherein both the non-flammable base and the flammable core are encased in a common shell.

Claims

A method of manufacturing of a pillar candle, comprising the steps of:
- forming (201) a shell (111);

- forming (202) a core (112) within the shell (111);

- introducing (203) a wick (130) into the core (112);

- wherein forming (201) the shell (111) is performed in a mould comprising a base (310) with a cavity (311) terminated by a lower stamp (312) movable within the cavity (311) and an upper stamp (320) configured to be introduced into the mould cavity (311) and comprises the steps of:
- providing (401, 501) a molten shell material into the mould cavity (311);

- introducing (403, 503) the upper stamp (320) into the mould cavity (311), thereby causing the molten shell material to fill in the free space between the outer walls of the upper stamp (320) and the inner walls of the cavity (311);

- solidifying (404, 504) the shell material; and

- pushing (405, 505) the shell (111) out of the mould cavity (311) by means of the lower stamp (312).
The method according to claim 1, comprising providing the molten shell material into the mould cavity (311) by pouring (401).
The method according to claim 1, comprising providing the molten shell material into the mould cavity (311) by spraying (501).
The method according to any of previous claims, further comprising, before providing (401, 501) the molten shell material into the mould cavity (311), spraying the walls of the cavity (311) with a liquid.
The method according to any of previous claims, comprising filling cooling channels (314) of the upper stamp (320), the lower stamp (312) and/or the base (310) with a cooling medium while solidifying (404, 504) the shell material.
The method according to any of previous claims, further comprising, after forming (202) the core (112) within the shell (111), introducing (204) a non-flammable base material into the shell (111) on the core (112) to form a non-flammable base (120).
The method according to claim 6, further comprising embedding the wick within the non-flammable base (120).
The method according to any of claims 6-7, further comprising pressing together (205) the shell (111), the core (112) and the non-flammable base (120).
The method according to any of claims 6-8, further comprising applying (206) a protective sheet (121) to the non-flammable base (120).